HYBRID CONTROL SYSTEM, Diagnostic DTC:P0A7A-203

DTC Code DTC Name
P0A7A-203 Generator Inverter Performance

DESCRIPTION

For a description of the inverter Click here.

DTC No. INF Code DTC Detection Condition Trouble Area
P0A7A 203 Malfunction (short circuit) in the generator inverter inside the inverter with converter assembly

  • Inverter with converter assembly

  • Hybrid vehicle generator assembly

  • Generator cable

CAUTION / NOTICE / HINT

CAUTION:


  • Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

  • After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals. After waiting for 10 minutes, check the voltage at the terminals in the inspection point in the inverter with converter assembly. The voltage should be 0 V before beginning work Click here.

    Tech Tips

    Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

Note


  • After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Click here.

  • DTC P0A7A-203 is stored after any of DTCs P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810 and 811 are stored. After troubleshooting and repairing DTC P0A7A-203, be sure to troubleshoot all the other DTCs.

  • Depending on the conditions in which the vehicle is being operated when a short circuit occurs in the inverter with converter assembly, the hybrid vehicle transaxle assembly may be affected. As this DTC is stored if a short circuit occurs in the inverter with converter assembly, it is necessary to perform a road test to check the hybrid vehicle transaxle assembly. If problems are found, replace the malfunctioning parts.

  • After completing the repair, including the repair of previously output DTCs, drive the vehicle at a speed of approximately 40 km/h (25 mph) for 1 minute and check that DTC P0A92-261 (Hybrid Generator Performance) is not output. If DTC P0A92-261 (Hybrid Generator Performance) is output, replace the hybrid vehicle generator assembly.

Tech Tips

After the repair, clear the DTCs and perform the following procedure to check that DTCs are not output.


  1. Turn the power switch on (READY) and wait for 5 seconds or more.

  2. Drive the vehicle for approximately 10 minutes mainly using the engine.

PROCEDURE


  1. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. B005XKK

      Remove the inverter cover from the inverter with converter assembly.

    3. Disconnect the generator cable and motor cable from the inverter with converter assembly.

    4. B005XELE02
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2 Shield Ground

      Check MG1 for an interphase short using a milliohmmeter.


      1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

        Tech Tips

        If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance
        Tester Connection Condition Specified Condition
        f1-1 (W) - f1-2 (U) Power switch off 89.5 to 98.9 mΩ
        f1-2 (U) - f1-3 (V) Power switch off 89.5 to 98.9 mΩ
        f1-3 (V) - f1-1 (W) Power switch off 89.5 to 98.9 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at 20°C (68°F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable and motor cable.

    7. Install the inverter cover.


    NG

    CHECK GENERATOR CABLE Click here

    OK

  2. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

  3. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810, 811 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810 and 811 are stored. After troubleshooting and repairing DTC P0A7A-203, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  4. CHECK GENERATOR CABLE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the generator cable.

    3. B005YI9E02
      Text in Illustration
      *1

      Generator Cable

      (Inverter with Converter Assembly Side)
      *2

      Generator Cable

      (Hybrid Vehicle Transaxle Assembly Side)
      *3 Shield ground

      Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-1 (W) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f1-3 (V) - Body ground and shield ground Power switch off 100 MΩ or higher

      Note

      Wrap the terminal of the three-phase AC cable with insulating tape to prevent them from coming into contact with body ground

    4. Measure the resistance according to the value(s) in the table below.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f1-1 (W) - f2-3 (W) Power switch off Below 1 Ω
      f1-2 (U) - f2-2 (U) Power switch off Below 1 Ω
      f1-3 (V) - f2-1 (V) Power switch off Below 1 Ω
      f1-1 (W) - f2-2 (U) Power switch off 100 MΩ or higher
      f1-2 (U) - f2-1 (V) Power switch off 100 MΩ or higher
      f1-3 (V) - f2-3 (W) Power switch off 100 MΩ or higher

    5. Install the generator cable.


    NG

    CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1) Click here

    OK

  5. REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY

    Click here


    NEXT

  6. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

  7. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810, 811 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810 and 811 are stored. After troubleshooting and repairing DTC P0A7A-203, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  8. CHECK HYBRID VEHICLE TRANSAXLE ASSEMBLY (MG1)

    CAUTION:

    Be sure to wear insulated gloves.


    1. Check that the service plug grip is not installed.

      Note

      After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair manual because this may cause a malfunction.

    2. Remove the inverter with converter assembly.

    3. Disconnect the generator cable from the hybrid vehicle transaxle assembly.

    4. A005BO8E02
      Text in Illustration
      *a Hybrid Vehicle Transaxle Assembly

      Check MG1 for an interphase short using a milliohmmeter.


      1. Using a milliohmmeter, measure the resistance according to the value(s) in the table below.

        Tech Tips

        If the MG1 temperature is high, the resistance will vary greatly from the specification. Therefore, measure the resistance at least 8 hours after the vehicle is stopped.

        Standard Resistance
        Tester Connection Condition Specified Condition
        f2-2 (U) - f2-1 (V) Power switch off 87.0 to 96.2 mΩ
        f2-1 (V) - f2-3 (W) Power switch off 87.0 to 96.2 mΩ
        f2-3 (W) - f2-2 (U) Power switch off 87.0 to 96.2 mΩ

        Tech Tips

        To correct the variation of the measured resistance due to temperature, use the following formula to calculate the resistance at 20°C (68°F).


        • R20 = Rt / {1 + 0.00393 X (T - 20)}

        The calculation is based on the following:


        • R20: Resistance at x 20°C (68°F) (mΩ)

        • Rt: Measured resistance (mΩ)

        • T: Temperature when the resistance is measured (°C)

    5. Using a megohmmeter set to 500 V, measure the resistance according to the value(s) in the table below.

      Note

      Be sure to set the megohmmeter to 500 V when performing this test. Using a setting higher than 500 V can result in damage to the component being inspected.

      Standard Resistance
      Tester Connection Condition Specified Condition
      f2-2 (U) - Body ground and shield ground Power switch off 100 MΩ or higher
      f2-1 (V) - Body ground and shield ground Power switch off 100 MΩ or higher
      f2-3 (W) - Body ground and shield ground Power switch off 100 MΩ or higher

    6. Connect the generator cable.

    7. Install the inverter with converter assembly.


    NG

    REPLACE GENERATOR CABLE Click here

    OK

  9. REPLACE GENERATOR CABLE

    Click here


    NEXT

  10. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

  11. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810, 811 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810 and 811 are stored. After troubleshooting and repairing DTC P0A7A-203, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here

  12. REPLACE GENERATOR CABLE

    Click here


    NEXT

  13. REPLACE HYBRID VEHICLE GENERATOR ASSEMBLY

    Click here


    NEXT

  14. REFER TO REPLACE INVERTER WITH CONVERTER ASSEMBLY PARTS


    1. Refer to replace inverter with converter assembly parts Click here.


    NEXT

  15. CHECK DTC OUTPUT (HYBRID CONTROL)


    1. Check the other DTCs that were output together with DTC P0A7A-203.

      Result
      DTC No. Relevant Diagnosis
      P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810, 811 Generator Inverter Performance

      Note

      DTC P0A7A-203 is stored after any of DTCs P0A7A-122, 130, 322, 324, 325, 517, 518, 809, 810 and 811 are stored. After troubleshooting and repairing DTC P0A7A-203, be sure to troubleshoot all the other DTCs.


    NEXT

    GO TO DTC CHART (HYBRID CONTROL SYSTEM) Click here